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At least 1,369 records · Page 76

A History of Aerospace Problems, Their Solutions, Their Lessons

The positive aspect of problem occurrences is the opportunity for learning and a challenge for innovation. The learning aspect is not restricted to the solution period of the problem occurrence, but can become the beacon for problem prevention on future programs. Problems/failures serve as a point of departure for scaling to new designs. To ensure that problems/failures and their solutions guide the future programs, a concerted effort has been expended to study these problems, their solutions, their derived lessons learned, and projections for future programs. This includes identification of technology thrusts, process changes, codes development, etc. However, they must not become an excuse for adding layers upon layers of standards, criteria, and requirements, but must serve as guidelines that assist instead of stifling engineers. This report is an extension of prior efforts to accomplish this task. Although these efforts only scratch the surface, it is a beginning that others must complete.

Ryan, R. S.↗

A Chebyshev Collocation Method for Moving Boundaries, Heat Transfer, and Convection During Directional Solidification

Free and moving boundary problems require the simultaneous solution of unknown field variables and the boundaries of the domains on which these variables are defined. There are many technologically important processes that lead to moving boundary problems associated with fluid surfaces and solid-fluid boundaries. These include crystal growth, metal alloy and glass solidification, melting and name propagation. The directional solidification of semi-conductor crystals by the Bridgman-Stockbarger method is a typical example of such a complex process. A numerical model of this growth method must solve the appropriate heat, mass and momentum transfer equations and determine the location of the melt-solid interface. In this work, a Chebyshev pseudospectra collocation method is adapted to the problem of directional solidification. Implementation involves a solution algorithm that combines domain decomposition, finite-difference preconditioned conjugate minimum residual method and a Picard type iterative scheme.

Zhang, Yiqiang↗

From the Chemistry Lab to Licensing

This is a story of technology maturation and transfer, and licensing. It traces the history of the recently patented ion- exchange material (IEM) from the accidental discovery that this polymer, a battery separator of marginal performance, picked up copper from distilled water passing through corroded copper tubing in the laboratory, to a point where five organizations and one individual have applied for licenses to manufacture and market it or to use it in a wide variety of applications. This story discusses in detail the problems of converting an immature technology into a mature and eventually commercialized technology, without dedicated resources. Readers will develop an appreciation for how the obstacles to maturation and licensing of the technology were faced and overcome. The lessons learned will be discussed, with the hope of enhancing the technology transfer process.

Savino, Joseph M.↗

Software Engineering Technology Infusion Within NASA

Abstract technology transfer is of crucial concern to both government and industry today. In this paper, several software engineering technologies used within NASA are studied, and the mechanisms, schedules, and efforts at transferring these technologies are investigated. The goals of this study are: 1) to understand the difference between technology transfer (the adoption of a new method by large segments of an industry) as an industry-wide phenomenon and the adoption of a new technology by an individual organization (called technology infusion); and 2) to see if software engineering technology transfer differs from other engineering disciplines. While there is great interest today in developing technology transfer models for industry, it is the technology infusion process that actually causes changes in the current state of the practice.

Zelkowitz, Marvin V.↗

NDE Methodologies for Composite Flywheels Certification

Manufacturing readiness of composite rotors and certification of flywheels depend in part on the maturity of nondestructive evaluation (NDE) technology for process optimization and quality assurance, respectively. Capabilities and limitations of x-ray-computed tomography and radiography, as well as advanced ultrasonics were established on NDE ring and rotor standards with EDM notches and drilled holes. Also, intentionally seeded delamination, tow break, and insert of bagging material were introduced in hydroburst-rings to study the NDE detection capabilities of such anomalies and their effect on the damage tolerance and safe life margins of subscale rings and rotors. Examples of possible occurring flaws or anomalies in composite rings as detected by NDE and validated by destructive metallography are shown. The general NDE approach to ensure quality of composite rotors and to help in the certification of flywheels is briefly outlined.

Baaklini, George Y.↗

Evaluation of Fieldbus and OPC for Advanced Life Support

FOUNDATION(Tm) Fieldbus and OP(TM) (OLE(TM)for Process Control) technologies were integrated into an existing control system for a crop growth chamber at NASA Ames Research Center. FOUNDATION(TM) Fieldbus is a digital, bi-directional, multi-drop, serial communications network which functions essentially as a LAN for sensors. FOUNDATION(TM) Fieldbus is heterarchical, with publishers and subscribers of data performing complex control functions at low levels without centralized control and its associated overhead. OPC(TM) is a set of interfaces which replace proprietary drivers with a transparent means of exchanging data between the fieldbus and applications. The objectives were: (1) to integrate FOUNDATION(TM) Fieldbus into existing ALS hardware and determine its overall effectiveness and reliability and, (2) to quantify any savings produced by using fieldbus and OPC technologies. We encountered several problems with the FOUNDATION(TM) Fieldbus hardware chosen. Our hardware exposed 100 data for each channel of the fieldbus. The fieldbus configurator software used to program the fieldbus was simply not adequate. The fieldbus was also not inherently reliable. It lost its settings twice during our tests for unknown reasons. OPC also had issues. It did not function at all as supplied, requiring substitution of some of its components with those from other vendors. It would stop working after a fixed period of time. Certain database calls eventually lock the machine. Overall, we would not recommend FOUNDATION(TM) Fieldbus: it was too difficult to implement with little overall added value. It also seems unlikely that FOUNDATION(TM) Fieldbus will gain sufficient penetration into the laboratory instrument market to ever be cost effective for the ALS community. OPC had good reliability and performance once a stable installation was achieved. It allowed a rapid change to an alternative software strategy when our first strategy failed. It is a cost effective solution to distributed control systems development.

Boulanger, Richard P.↗

Commercial Research and Development: Power to Explore, Opportunities from Discovery

The technical and economic goals of commercial use of space are laudable, and are addressed as a high priority by almost every national space program and most major aerospace companies the world over. Yet, the focus of most organizational agendas and discussions tends to focus on one or two very narrow enabling aspects of this potentially large technological and economic opportunity. While government sponsored commercial launch activities and private space platforms are an integral part of efforts to leverage the commercial use of space, these activities are possibly one of the smallest parts of creating, a viable and sustainable market for the commercial use of space. Most of the current programs usually do not appropriately address some of the critical issues of the current, already interested, potential space user communities. Current programs place the focus of the majority of the user requirements on the vehicle payload weight and mass performance considerations as the primary payload economical factor in providing a commercial market with a stimulating price for gaining access to the space environment. The larger user challenges of transformation from Earth-based research and development approaches to space environment approaches are not addressed early enough in programs to impact the new business considerations of potential users. Currently, space-based research and development user activities require a large user investment in time, in development of new areas of support expertise, in development of new systems, in risk of schedule to completion, and in long term capital positioning. The larger opportunities for stimulating a strong market driven interest in commercial use of space that could result from the development of vehicle payload "leap ahead technologies" for users are being missed, and there is a real risk of limiting the potentially broader market base to support a more technologically advanced and economically lucrative outcome. A major driving force for strengthening the commercial space activities is not only the technological advances in launch vehicle, or newer satellites, but the myriad of enabling payloads technologies that could, as a goal, result in an almost transparent facilitation to regular CD a, -n access to space and microgravity environments by the future users from the existing Earth-based research and development organizations market segments. Rather than focusing only on developing high lift performance launch vehicles and then developing payloads to fit them, the real focus from a business model perspective should to be on the customer payloads requirements, and on designing launch vehicles and platforms systems for a space transportation and facility infrastructure to support all aspects of the business model for the user market. To harness the full potential of space commercialization, new efforts need to be made to comprehensively examine all the critical business model areas for commercial research, development, and manufacturing in space so as to identify specific products and efforts; to determine how such operations must be both similar to and different from current Earth-based activities; to evaluate the enabling technological devices, processes and efforts so that like efforts can be addressed in a synergistic fashion for maximum user cost effectiveness; to delineate the services that are both needed and can be provided by such activities; and to use this information to drive design and development of space commercialization efforts and policy.

Casas, Joseph C.↗

Advanced Material Developments with Laser Engineered Net Shaping

The Laser Engineered Net Shaping (LENS(Trademark)) process is a new technology to fabricate three-dimensional metallic components directly from CAD solid models. It directly fabricates metal hardware by injecting the metal powder of choice into the focal point of a 700W Nd:Yag laser as it traces the perimeter and fills of a part. The Rapid Prototype Laboratory at Marshall Space Flight Center is currently operating a OPTOMEC 750 LENS machine in evaluation experiments involving integration of this technology into various manufacturing processes associated with aerospace applications. This paper will cover our research finding about properties of samples created from Inconel 718 & SS316 using this process versus the same materials in cast & wrought conditions.

Williams, Glenn A.↗

Space Ops 2002: Bringing Space Operations into the 21st Century. Track 3: Operations, Mission Planning and Control. 2nd Generation Reusable Launch Vehicle-Concepts for Flight Operations

With the successful implementation of the International Space Station (ISS), the National Aeronautics and Space Administration (NASA) enters a new era of opportunity for scientific research. The ISS provides a working laboratory in space, with tremendous capabilities for scientific research. Utilization of these capabilities requires a launch system capable of routinely transporting crew and logistics to/from the ISS, as well as supporting ISS assembly and maintenance tasks. The Space Shuttle serves as NASA's launch system for performing these functions. The Space Shuttle also serves as NASA's launch system for supporting other science and servicing missions that require a human presence in space. The Space Shuttle provides proof that reusable launch vehicles are technically and physically implementable. However, a couple of problems faced by NASA are the prohibitive cost of operating and maintaining the Space Shuttle and its relative inability to support high launch rates. The 2nd Generation Reusable Launch Vehicle (2nd Gen RLV) is NASA's solution to this problem. The 2nd Gen RLV will provide a robust launch system with increased safety, improved reliability and performance, and less cost. The improved performance and reduced costs of the 2nd Gen RLV will free up resources currently spent on launch services. These resource savings can then be applied to scientific research, which in turn can be supported by the higher launch rate capability of the 2nd Gen RLV. The result is a win - win situation for science and NASA. While meeting NASA's needs, the 2nd Gen RLV also provides the United States aerospace industry with a commercially viable launch capability. One of the keys to achieving the goals of the 2nd Gen RLV is to develop and implement new technologies and processes in the area of flight operations. NASA's experience in operating the Space Shuttle and the ISS has brought to light several areas where automation can be used to augment or eliminate functions performed by crew and ground controllers. This experience has also identified the need for new approaches to staffing and training for both crew and ground controllers. This paper provides a brief overview of the mission capabilities provided by the 2nd Gen RLV, a description of NASA's approach to developing the 2nd Gen RLV, a discussion of operations concepts, and a list of challenges to implementing those concepts.

Hagopian, Jeff↗

Carbon Fiber Reinforced Ceramic Composites for Propulsion Applications

Fiber reinforced ceramic composites are materials of choice for gas turbine engines because of their high thermal efficiency, thrust/weight ratio, and operating temperatures. However, the successful introduction of ceramic composites to hot structures is limited because of excessive cost of manufacturing, reproducibility, nonuniformity, and reliability. Intense research is going on around the world to address some of these issues. The proposed effort is to develop a comprehensive status report of the technology on processing, testing, failure mechanics, and environmental durability of carbon fiber reinforced ceramic composites through extensive literature study, vendor and end-user survey, visits to facilities doing this type of work, and interviews. Then develop a cooperative research plan between NASA GRC and NCA&T (Center for Composite Materials Research) for processing, testing, environmental protection, and evaluation of fiber reinforced ceramic composites.

Freedman, Marc↗

Growing Larger Crystals for Neutron Diffraction

Obtaining crystals of suitable size and high quality has been a major bottleneck in macromolecular crystallography. With the advent of advanced X-ray sources and methods the question of size has rapidly dwindled, almost to the point where if one can see the crystal then it was big enough. Quality is another issue, and major national and commercial efforts were established to take advantage of the microgravity environment in an effort to obtain higher quality crystals. Studies of the macromolecule crystallization process were carried out in many labs in an effort to understand what affected the resultant crystal quality on Earth, and how microgravity improved the process. While technological improvements are resulting in a diminishing of the minimum crystal size required, neutron diffraction structural studies still require considerably larger crystals, by several orders of magnitude, than X-ray studies. From a crystal growth physics perspective there is no reason why these 'large' crystals cannot be obtained: the question is generally more one of supply than limitations mechanism. This talk will discuss our laboratory s current model for macromolecule crystal growth, with highlights pertaining to the growth of crystals suitable for neutron diffraction studies.

Pusey, Marc↗

Data Acquisition and Control Systems Laboratory

The Data Acquisition and Control Systems (DACS) Laboratory is a facility at Stennis Space Center that provides an off test-stand capability to develop data-acquisition and control systems for rocket-engine test stands. It is also used to train new employees in state-of-the-art systems, and provides a controlled environment for troubleshooting existing systems, as well as the ability to evaluate the application of new technologies and process improvements. With the SSC propulsion testing schedules, without the DACS Laboratory, it would have been necessary to perform most of the development work on actual test systems, thereby subjecting both the rocket-engine testing and development programs to substantial interference in the form of delays, restrictions on modifications of equipment, and potentially compromising software configuration control. The DACS Laboratory contains a versatile assortment of computer hardware and software, digital and analog electronic control and data-acquisition equipment, and standard electronic bench test equipment and tools. Recently completed Control System development and software verification projects include support to the joint NASA/Air Force Integrated Powerhead Demonstration (IPD) LOX & LH2 PreBurner and Turbopump ground testing programs. In other recent activities, the DACS Laboratory equipment and expertise have supported the off-stand operation of high-pressure control valves to correct valve leak problems prior to installation on the test stand. Future plans include expanding the Laboratory's capabilities to provide cryogenic control valve characterization prior to installation, thereby reducing test stand activation time.

Holland, Randy↗

Fabrication of Microshutter Arrays for James Webb Space Telescope

Two-dimensional MEMS microshutter arrays are being developed at NASA Goddard Space Flight Center for use in the near-infrared region on the Next Generation Space Telescope (NGST). The microshutter arrays are designed for the selective transmission of light with high efficiency and high contrast. The NGST environment requires cryogenic operation at 45K. Microshutter arrays are fabricated out of silicon-oxide-insulated (SOI) silicon wafers. Arrays are close-packed silicon nitride membranes with a pixel size of 100x100 microns. Individual shutters are patterned with a torsion flexure permitting shutters to open 90 degrees with a minimized mechanical stress concentration. The mechanical shutter arrays are fabricated using MEMS technologies. The processing includes a multi-layer metal deposition and patterning of shutter electrodes and magnetic pads, reactive ion etching (RE) of the front side to form shutters out of the nitride membrane, an anisotropic back-etch for wafer thinning, followed by a deep RIE (DRIE) back-etch down to the nitride shutter membrane to form frames and relieve shutters from the silicon substrate. An additional metal deposition and patterning is used to form back electrodes. Shutters are actuated using a magnetic force and latched using an electrostatic force.

Li, Mary J.↗

Estimating Logistics Support of Reusable Launch Vehicles During Conceptual Design

Methods exist to define the logistics support requirements for new aircraft concepts but are not directly applicable to new launch vehicle concepts. In order to define the support requirements and to discriminate among new technologies and processing choices for these systems, NASA Langley Research Center (LaRC) is developing new analysis methods. This paper describes several methods under development, gives their current status, and discusses the benefits and limitations associated with their use.

Morris, W. D.↗

Microshutter Arrays for James Webb Space Telescope

Two-dimensional MEMS microshutter arrays are being developed at NASA Goddard Space Flight Center for use in the near-infrared region on the James Webb Space Telescope (JWST). The microshutter arrays are designed for the selective transmission of light with high efficiency and high contrast. The JWST environment requires cryogenic operation at 35K. Microshutter arrays are fabricated out of silicon-oxide-insulated (SOI) silicon wafers. Arrays are close-packed silicon nitride membranes with a pixel size of 100x200 p. Individual shutters are patterned with a torsion flexure permitting shutters to open 90 degrees with a minimized mechanical stress concentration. The mechanical shutter arrays are fabricated using MEMS technologies. The processing includes a multi- layer metal deposition and patterning of shutter electrodes and magnetic pads, reactive ion etching (NE) of the front side to form shutters out of the nitride membrane, an anisotropic back-etch for wafer thinning, followed by a deep RIE (DRIE) back-etch down to the nitride shutter membrane to form W e s and relieve shutters from the silicon substrate. An additional metal deposition and patterning is used to form back electrodes. Shutters are actuated using a magnetic force and latched using an electrostatic force. . . . KEYWORDS: microshutter, MEMS, RIE, DRIE, micro-optics, near inbred, space telescope

Li, Mary J.↗

Innovative, Inexpensive Etching Technique Developed for Polymer Electro- Optical Structures

Electro-optic, polymer-based integrated optic devices for high-speed communication and computing applications offer potentially significant advantages over conventional inorganic electro-optic crystals. One key area of integrated optical technology--primary processing and fabrication--may particularly benefit from the use of polymer materials. However, as efforts concentrate on the miniaturization of electro-integrated circuit pattern geometries, the ability to etch fine features and smoothly sloped sidewalls is essential to make polymers useful for electro-integrated circuit applications. There are many existing processes available to etch polymer materials, but they all yield nearly vertical sidewalls. Vertical sidewalls are too difficult to reliably cover with a metal layer, and incomplete metalization degrades microwave performance, particularly at high frequency. However, obtaining a very sloped sidewall greatly improves the deposition of metal on the sidewall, leading to low-loss characteristics, which are essential to integrating these devices in highspeed electro-optic modulators. The NASA Lewis Research Center has developed in-house an inexpensive etching technique that uses a photolithography method followed by a simple, wet chemical etching process to etch through polymer layers. In addition to being simpler and inexpensive, this process can be used to fabricate smoothly sloped sidewalls by using a commercial none rodible mask: Spin-On-Glass. A commercial transparent material, Spin-On-Glass, uses processes and equipment similar to that for photoresist techniques.

Nguyen, Hung D.↗

Nondestructive Evaluation Methodologies Developed for Certifying Composite Flywheels

Manufacturing readiness of composite rotors and certification of flywheels depend in part on the maturity of nondestructive evaluation (NDE) technology for process optimization and quality assurance, respectively. At the NASA Glenn Research Center, the capabilities and limitations of x-ray-computed tomography and radiography, as well as advanced ultrasonics were established on NDE ring and rotor standards with electrical discharge machining (EDM) notches and drilled holes. Also, intentionally seeded delamination, tow break, and insert of bagging material were introduced in hydroburst-rings to study the NDE detection capabilities of such anomalies and their effect on the damage tolerance and safe life margins of subscale rings and rotors. Examples of possible occurring flaws or anomalies in composite rings as detected by NDE and validated by destructive metallography are shown. The general NDE approach to ensure the quality of composite rotors and to help in the certification of flywheels is briefly outlined.

Baaklini, George Y.↗

A Method for Assessing the Accuracy of a Photogrammetry System for Precision Deployable Structures

The measurement techniques used to validate analytical models of large deployable structures are an integral Part of the technology development process and must be precise and accurate. Photogrammetry and videogrammetry are viable, accurate, and unobtrusive methods for measuring such large Structures. Photogrammetry uses Software to determine the three-dimensional position of a target using camera images. Videogrammetry is based on the same principle, except a series of timed images are analyzed. This work addresses the accuracy of a digital photogrammetry system used for measurement of large, deployable space structures at JPL. First, photogrammetry tests are performed on a precision space truss test article, and the images are processed using Photomodeler software. The accuracy of the Photomodeler results is determined through, comparison with measurements of the test article taken by an external testing group using the VSTARS photogrammetry system. These two measurements are then compared with Australis photogrammetry software that simulates a measurement test to predict its accuracy. The software is then used to study how particular factors, such as camera resolution and placement, affect the system accuracy to help design the setup for the videogrammetry system that will offer the highest level of accuracy for measurement of deploying structures.

Moore, Ashley↗